Magnetic devices with integral cooling channels

ABSTRACT

A magnetic device includes an electrically insulating body and a conductor coil. The insulating body defines an internal cavity for a magnetic device core and a coolant channel routed about the internal cavity. The conductor coil extends through the insulating body and winds about the internal cavity. The electrically insulating body electrically insulates the internal cavity and coolant channel from the conductor coil.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 14/183,700, filed Feb. 19, 2014, which claims priority to andthe benefits of U.S. Provisional Application No. 61/887,052, filed Oct.4, 2013, the contents which are incorporated by reference herein in itsentirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure relates to power electronic devices, and moreparticularly to thermal management of magnetics for power electronicdevices.

2. Description of Related Art

Vehicle power buses typically power multiple devices with differentpower requirements from a single power source. The powered devicestherefore need to adapt the current received from the power source sothat it is suitable for the powered device. Typically, the powereddevice includes a power conditioner for converting the power, such as byrectifying, inverting, or filtering the current to remove signals ornoise, e.g. variation, from received current. Wound magnetics can beused in power conditioners to convert or filter current.

Conventional wound magnetics are passive electrical devices that includea magnetic core and a conductor coil wound about the core. The coregenerates a persistent magnetic field and current flowing through thewindings generates a variable magnetic field. The persistent andvariable magnetic fields oppose one another with the persistent magneticfield opposing current flow change in the windings. This oppositionremoves noise carried in the current by smoothing the change in thecurrent flowing through the conductor. The level of the filtering of themagnetic device is a function of the strength of the persistent magneticfield of the magnetic device core. Magnetic field strength is in turn afunction of the core temperature.

One problem with conventional magnetics is that current flowing throughthe magnetic device windings produces heat due to resistive heatingassociated with the current flow. The heat can migrate into the magneticdevice core, raising its temperature, and change the strength of thefield generated by the core. This alters the filtering effect providedby the magnetics, potentially exposing the powered device current withunacceptable levels of variation.

Conventional magnetics have generally been considered satisfactory fortheir intended purpose. However, there is a need in the art for improvedsystems and methods for temperature control of magnetics. There alsoremains a need in the art for such systems and methods that are easy tomake and use. The present disclosure provides a solution for theseproblems.

SUMMARY OF THE INVENTION

A magnetic device includes an electrically insulating body and aconductor coil. The insulating body defines an internal cavity for amagnetic device core and a coolant channel routed about the internalcavity. The conductor coil extends through the insulating body, aboutthe cavity. The insulating body electrically insulates the internalcavity from the coolant channel and separates the coolant channel fromthe conductor coil.

In certain embodiments, the magnetic device includes an integral housingsurrounding the magnetic device body and conductor coil. The housing candefine a fluid conduit external to the insulating body for supplyingcoolant to the cooling channel defined by the insulating body. Thehousing can further define a cold plate for cooling coolant flowingthrough the fluid conduit. The insulating body, conductor coil andhousing can be integrally formed using an additive manufacturingprocess.

In accordance with certain embodiments, the insulating body and housingdefine a coolant inlet fluidly connecting the coolant channel with thefluid conduit for supplying coolant to the magnetic device. Theinsulating body and housing can also define a coolant outlet fluidlyconnecting the coolant channel to the fluid conduit. The coolant channelcan be a first coolant channel, and the insulating body can define asecond coolant channel also extending about the internal cavity. Abridging channel defined by the insulating body can fluidly connect thefirst and second coolant channels in series. The coolant channel can bea flow structure arranged between the conductor coil and cavity forthermally shielding the cavity from heat generated by current flowingthrough the conductor coil.

It is contemplated that the fluid conduit can be thermally coupled to acold plate and the cold plate mechanically coupled to the insulatorhousing. The cold plate can be integrally formed with the housing andcan define therein the fluid conduit for connection with the coolantchannel.

A motor controller includes a magnetic device and a housing as describedabove, wherein the housing and insulating body are integral with oneanother. The housing encloses the insulating body. A coolant inlet and acoolant outlet are fluidly connected with the coolant channel forremoving heat generated by resistive heating of the conductor coil. Theinsulating body defines a flow structure fluidly connected to thecoolant channel and extending about the cavity of the insulating body.

In certain embodiments, the magnetic device includes a magnetic devicecore with a linear shape disposed within the cavity of the insulatingbody. The cavity defined by the insulating body can have a toroid shape.It is also contemplated that the magnetic device core can also have atoroid shape, and the insulating body can be conformally disposed aboutthe surface of the magnetic device core.

A method of making a magnetic device includes fabricating a firstportion of a magnetic device housing, insulating body, and conductorcoil. Fabricating the first portion of the insulating body includesdefining a socket in the insulating body. The method also includesseating a magnetic device core in the socket defined by the insulatingbody and fabricating a second portion of the insulating body such thatthe socket forms a portion of a cavity occupied by the magnetic devicecore. Fabricating the first and second portions of the insulating bodyincludes defining a coolant channel within the insulating body.

It is contemplated that forming the first portion of the magnetic deviceincludes integrally forming the first portion using an additivemanufacturing process. Forming the second portion of the magnetic devicecan also include integrally forming the second portion using an additivemanufacturing process. It is contemplated that the magnetic device corecan be integral with an integrally formed housing, conductor coil,insulating body, and coolant channel flow structure.

These and other features of the systems and methods of the subjectdisclosure will become more readily apparent to those skilled in the artfrom the following detailed description of the preferred embodimentstaken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosureappertains will readily understand how to make and use the devices andmethods of the subject disclosure without undue experimentation,preferred embodiments thereof will be described in detail herein belowwith reference to certain figures, wherein:

FIG. 1 is a perspective view of an exemplary embodiment of a magneticdevice constructed in accordance with the present disclosure, showingthe magnetic device housing;

FIG. 2 is a cross-sectional perspective view of the magnetic device ofFIG. 1, showing the insulating body, conductor coil, and coolant channeldefined by the insulating body;

FIG. 3 is cross-sectional side elevation view of the magnetic device ofFIG. 2, showing the arrangement of the conductor coil and coolantchannel defined by the insulating body;

FIG. 4 is a cross-sectional perspective view of the magnetic device ofFIG. 1, showing an magnetic device core being received within the cavitydefined by the insulating body following fabrication of the a firstportion of the magnetic device;

FIG. 5 is a cross-sectional perspective view of the magnetic device ofFIG. 1, showing the magnetic device core disposed within the cavityduring fabrication of a second portion of the magnetic device;

FIG. 6 is a partial cross-sectional perspective view of the magneticdevice of FIG. 1 showing the arrangement of the coolant channel,conductor coil, and magnetic device core within the housing and magneticdevice body; and

FIG. 7 is cross-sectional side elevation view of the magnetic device ofFIG. 1, showing conductor coils and cooling channels about the core.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made to the drawings wherein like referencenumerals identify similar structural features or aspects of the subjectdisclosure. For purposes of explanation and illustration, and notlimitation, a partial view of an exemplary embodiment of the magneticdevice in accordance with the disclosure is shown in FIG. 1 and isdesignated generally by reference character 100. Other embodiments ofmagnetic device in accordance with the disclosure, or aspects thereof,are provided in FIGS. 2-7, as will be described. The systems and methodsdescribed herein can be used for power conversion devices, suchinductors, transformers, and chokes for motor controllers for example.

FIG. 1 shows a motor controller 10 including a magnetic device 100coupled to a cold plate 140 constructed in accordance with the presentdisclosure. Magnetic device 100 includes an insulating body 110 andconductor coil 120 substantially disposed, e.g. entirely, with a housing130. A fluid conduit 142 extends between cold plate 140 and a lowerportion of housing 130. Fluid conduit 142 is configured for receiving acoolant flow at a conduit entrance, channeling the flow through magneticdevice 100, and more specifically through insulating body 110, forremoving heat from magnetic device 100, and dispatching the flow througha conduit exit. Fluid conduit 142 is thermally communicative with coldplate 140, and in the illustrated embodiment is defined within coldplate 140. This allows for efficient heat transfer as there is nointervening material or layers separating cold plate 140 and fluidconduit 142 that could otherwise impede heat transfer between theelements.

With reference to FIG. 2, insulating body 110 is disposed with housing130 and is formed from an electrically insulating material forelectrically insulating conductor coil 120. Insulating body 110 definesan internal cavity 124 configured for seating a magnetic device core.Cavity 124 has an inner surface that is conformal and configured fordirect contact with the surface of magnetic device core 150 seated incavity 124. This minimizes the volume occupied by magnetic device 100.In the illustrated embodiment cavity 124 has a toroid shapecorresponding to a toroid shaped magnetic device core. As will beappreciated by those skilled in the art, cavity 124 can be suitablyshaped to seat a magnetic device core having an appropriate shape assuitable for a given application of magnetic device 100.

Insulating body 110 defines a coolant channel 122. Coolant channel 122extends through insulating body 110 between a conductor coil 120 formedwith insulating body 110. Coolant channel 122 may be a single channelcircuitously extending about insulating body 110 or can include aplurality of coolant channels extending from a manifold structuredefined within insulating body 110. In the illustrated embodiment,coolant channel 122 includes a plurality channels arranged about acircumference of cavity 124 and defining a flow structure. The flowstructure creates a curtain-like cooling effect between cavity 124 andconductor coil 120, operating to thermally isolate cavity 124 fromconductor coil 120. This allows a magnetic device core 150 (shown inFIG. 4) to be maintained at a uniform temperature not withstanding heatgenerated by conductor coil 120. This in turn allows the magnetic devicecore to have a persistent magnetic field with uniform strength, allowingmagnetic device 100 to filter current flowing through conductor coil 120consistently notwithstanding variation in the current flow.

With reference to FIG. 3, coolant channel 122 fluidly connects to fluidconduit 142 through a coolant inlet 132 and a coolant outlet 134.Coolant inlet 132 and coolant outlet 134 are each defined by bothinsulating body 110 and housing 130. Insulating body 110 and housing 130also define electrical connections 126 and 128 to conductor coil 120 forelectrically connecting conductor coil 120 to voltage terminals andflowing current through conductor coil 120. Conductor coil 120 passesthrough cavity 124 at least once, and is formed from an electricallyconductive material, such as copper for example.

Both conductor coil 120 and coolant channel 122 extend through or aroundthe cavity 124. In the illustrated embodiment, coolant channel 122 iscloser to cavity 124 than corresponding conductor coil 120. Thisprovides a coolant curtain arranged about the conductor. Insulating body110, conductor coil 120, and housing 130 are integral with one another.Insulating body 110 constructed to conformally surround conductor coil120 and magnetic device core 150. Housing 130 is constructed so as toconformally envelope insulating body 110. Insulating body 110, conductorcoil 120, and housing 130 are integrally formed using an additivemanufacturing process. Using an additive manufacturing process enablesprecisely locating coolant channel 122 between cavity 124 and conductorcoil 120. It also allows for provisioning magnetic device 150 withcooling channels without structure independent of insulating body 110.This prevents heat generated by conductor coil 120 from soaking intomagnetic device core 150 during continuous operation because coolantchannels can be arranged relatively closely to conductor coils. It alsoallows for cooling without use of an intermediary material thatotherwise requires heat to transfer from the insulating body, through acoolant channel wall material, and into the coolant flow. The additivemanufacturing process involves the successive addition of metal orthermally conductive polymeric materials to form the housing,conductors, or insulating body using energy from an ultrasonictransducer, laser, electron beam, or cold spray technology. Theinsulating body could also be deposited using a direct write technologysuch as, but not limited to, aerosol jetting or injection molding forexample. As will be appreciated by those skilled in the art, anysuitable process can be used to manufacture a magnetic device inaccordance with the present disclosure.

With reference to FIGS. 4 and 5, a “bottom-up” method of fabricatingmagnetic device, e.g. magnetic device 100, is shown. The method is“bottom-up” in the sense that the magnetic device is constructed over asubstrate, e.g. cold plate 140. The method includes integrally forming afirst portion (shown in FIG. 5) of the magnetic device using an additivemanufacturing process, seating a magnetic device core, e.g. magneticdevice core 150, into the magnetic device, and integrally forming asecond portion of the magnetic device using the additive manufacturingprocess. Forming the first portion of the magnetic device can alsoinclude forming first portions of an insulating body, e.g. insulatingbody 110, defining a cavity, coolant channels extending about thecavity, and a conductor coil winding about the cavity. Forming thesecond portion of the magnetic device can also include forming secondportions (shown in FIG. 5) of the insulating body including secondportions of the coolant channel, cavity, and conductor coil. Forming aninsulating body defining a coolant channel provides a magnetic devicewherein there is only a single material, e.g. layer, between theconductor coil and the heat transfer medium. This provides for efficientcooling of the magnetic device as there is no mismatch in thermalconductivities between different materials disposed between theconductor coil and coolant channel. As will be appreciated by thoseskilled in the art, the cold plate can also be fabricated using anadditive manufacturing process. As will also be appreciated, method 200can also be a “top-down” method wherein the upper portion of housing 130is constructed as part of the first portion and cold plate 140 isconstructed afterwards as part of the second portion.

With reference to FIGS. 6 and 7, magnetic device 100 is shown inperspective partial cross-section and cross-sectional elevation views.Insulating body 110 and housing 130 define a coolant inlet 132 fluidlyconnecting a coolant channel 122 defined in insulating body 110 and acold plate 140 with a fluid conduit 142 for supplying coolant tomagnetic device 100. Insulating body 110 and housing 130 also define acoolant outlet 134 fluidly connecting coolant channel 122 to fluidconduit 142. Coolant channel 122 includes a first coolant channel and asecond coolant channel, each channel extending about a portion ofmagnetic device core 150 and extending about magnetic device core 150. Abridging channel 108 defined by the insulating body fluidly connects thefirst and second coolant channels in series. Coolant channel 122 definesa flow structure arranged between conductor coil 120 and cavity forthermally shielding the cavity from heat generated by current flowingthrough the conductor coil. In the illustrated embodiment, the flowstructure defines a plurality of relatively small coolant channelspositioned between conductor coil 120 and magnetic device core 150.

Conventional magnetics are some of the largest components within certaintypes of electronic packages. Magnetic device size can be driven by theability to cool the magnetic device core, particularly in magnetics withcore materials that require lower operating temperatures. Using additivemanufacturing to fabricate the housing, conductor coil, and coolingchannels about the core cavity provides efficient cooling of the coreand thermal isolation of the core from the windings. This is additivemanufacturing process allows for fabrication of complex coolant channelstructures within the magnetic device, allowing for cooling the corewhile operating the conductor coil at much higher temperatures. Having acoolant channel integrated directly into the cold plate further allowsfor supplying coolant to the coolant channel structure without the riskof leakage in coolant channel to cold plate interfaces associated withconventionally machined cold plates and coolant channels. This allowsfor construction of smaller magnetics using higher performance lowtemperature materials, including but not limited to Metglas® ornanocrystalline cores.

The methods and systems of the present disclosure, as described aboveand shown in the drawings, provide for magnetics and motor controllerswith superior properties including thermal isolation of the magneticdevice core from heat resistively generated by the magnetic deviceconductor coil. While the apparatus and methods of the subjectdisclosure have been shown and described with reference to preferredembodiments, those skilled in the art will readily appreciate thatchanges and/or modifications may be made thereto without departing fromthe spirit and scope of the subject disclosure.

1-9. (canceled)
 10. A motor controller, comprising: a magnetic devicecomprising: an electrically insulating body, defining: an internalcavity for a magnetic device core; a coolant channel routed about theinternal cavity; and a flow structure fluidly connected to the coolantchannel, defined by the insulating body, and extending about the cavityof the insulating body; a conductor coil extending through theinsulating body, wherein the insulating body electrically insulates theinternal cavity from the coolant channel and electrically insulates thecoolant channel from the conductor coil; an integral housing surroundingthe magnetic device; and a cold plate coupled to the magnetic device andhaving a fluid conduit defined therein, wherein the fluid conduit isfluidly connected to the coolant channel by a coolant inlet extendingthrough the cold plate and the insulating body, wherein the fluidconduit is fluidly connected to the coolant channel by a coolant outletextending through the cold plate and the insulating body.
 11. A motorcontroller as recited in claim 10, wherein the insulating body andhousing are integrally formed in an additive manufacturing process. 12.A motor controller as recited in claim 10, wherein the cavity defined bythe insulating body has a toroid shape.
 13. A motor controller asrecited in claim 12, further comprising a magnetic device core with atoroid shape, wherein the insulating body is conformally disposed abouta surface of the magnetic device core. 14-15. (canceled)
 16. A method amaking a magnetic device, comprising: integrally fabricating firstportion of a magnetic device housing, an insulating body, and aconductor coil; seating a magnetic device core in the first portion ofthe insulating body; and integrally fabricating second portions of themagnetic device housing, the insulating body, and the conductor coil onrespective first portions of the magnetic device housing, insulatingbody, and conductor coil; wherein a surface of the magnetic device coreis surrounded by the first and second portions of the insulating body,and wherein the insulating body electrically insulates the internalcavity from the coolant channel.
 17. A method as recited in claim 16,wherein one of the integrally fabricating first and second portions ofthe magnetic device housing, the insulating body, and the conductor coilincludes using an additive manufacturing process.
 18. A method asrecited in claim 16, wherein fabricating first and second portions ofthe insulating body includes defining a flow structure within theinsulating body.
 19. A method as recited in claim 16, wherein theinsulating body is conformal with a surface of the magnetic device core.20. A method as recited in claim 16, further comprising defining acoolant inlet in the insulating body, wherein the coolant inlet isfluidly connected to the coolant channel.
 21. A method as recited inclaim 20, further comprising coupling a cold plate to the electricallyinsulating body such that a fluid conduit defined therein is fluidlyconnected to the coolant channel through the coolant inlet.
 22. A methodas recited in claim 16, further comprising defining a coolant outlet inthe insulating body fluidly, wherein the coolant outlet is fluidconnected to the coolant channel.
 23. A method as recited in claim 22,further comprising coupling a cold plate to the electrically insulatingbody such that a fluid conduit defined therein is fluidly connected tothe coolant channel through the coolant outlet.
 24. A method a making amagnetic device, comprising: integrally fabricating first portion of amagnetic device housing, an insulating body, and a conductor coil;seating a magnetic device core in the first portion of the insulatingbody; integrally fabricating second portions of the magnetic devicehousing, the insulating body, and the conductor coil on respective firstportions of the magnetic device housing, insulating body, and conductorcoil; defining a coolant inlet in the insulating body, wherein thecoolant inlet is fluidly connected to the coolant channel; and couplinga cold plate to the electrically insulating body such that a fluidconduit defined therein is fluidly connected to the coolant channelthrough the coolant inlet, wherein a surface of the magnetic device coreis surrounded by the first and second portions of the insulating body,wherein the insulating body electrically insulates the internal cavityfrom the coolant channel.